ESAB subsidiaries and representative offices eS 2015 E18 kenga cating Pre ARCAIR ia ee AIR CARBON-ARC MANUAL GOUGING TORCHES Operating Manual English Revision: AC |lssu Date: June 15,2017 Manali. 8250012ARCAIR WE APPRECIATE YOUR BUSINESS! Congratulations on receiving your new Arcair® product. We are proud to have you as our customer and will strive to provide you with the best service and support in the industry. This product is backed by our extensive warranty and world-wide service network. We know you take pride in your work and we feel privileged to provide you with this high performance product that will help you get the job done. For more than 60 years Arcair has provided quality products you can trust, when your reputation is on the line. YOU ARE IN GOOD COMPANY! Arcairis a global brand of cutting products for ESAB. We distinguish ourselves from our competition through market-leading innovation and truly dependable products that will stand the test of time. We strive to enhance your productivity, efficiency and welding performance, enabling you to excel in your craft. We design products with the welder in mind delivering- advanced features, durability, ease of use and ergonomic comfort. Above all, we are committed to a safer working environment within the welding industry. Your satisfaction with this product and its safe operation is our ultimate concern. Please take the time to read the entire manual, especially the Safety Precautions. It you have any questions or concerns regarding your new Arcair product, please contact our friendly and knowledgeable Customer Service Team at: 1-800-462-2782 (USA) and 1-905-827-4515 (Canada), or visit us on the web at www.esab.com/arcair STATEMENT OF WARRANTY LInMITED WARRANTY: ESAB warrants that its products wi be tree of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period ap- plicable to the ESAB products as stated below, ESAB shall, upon written notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with ESAB's specifications, instructions, recommendations and recognized standard industry prectice, and not been subject to misuse, repair, neglect, alteration, or accident, corect such defects by suitable repair or replacement, at ESAB's sole option, of any components oF parts ofthe product determined by ESAB tobe defective, ‘THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. LIMITATION OF LIABILITY: ESAB shall not under any circumstances be lable for special in- direct or consequential damages, such as, but not imited to, damage or loss of purchased or replacement goods, business interruption or loss of profi, or ctaims of customers of distributor (hereinafter the *Purchaser’) fr service interruption. The remedies ofthe Purchaser set forth herein are exclusive and the lability of ESAB with respect to any contract, or anything done in connection therewith such as the performance or breach thereaf, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by ESAB whether arising cut of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based ‘THis WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY ESAB PRODUCT. ‘THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS. This warranty is effective forthe time stated inthe Warranty Schedule beginning on the date tha the authorized distribulor delivers the products tothe Purchaser. ‘Warranty repairs or replacement claims under this imited warranty must be submitted by an authorized ESAB repair facility within thirty (30) days ofthe repai. No transportation costs of any kind wil be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibilty ofthe Purchaser Al returned goods shall be al the Purchaser’ risk and expense. This warranty supersedes all previous ESAB warranties.This Page Intentionally Blank A WARNINGS Read and understand this entire Manual end your employer's safety prac- tices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manutac- turer's best judgement, the Manufacturer assumes no lability for its use, ‘Arcair® K3000™ & K4000° Air Carbon-Are Manual Gouging Torches Operating Manual Operating Manual Guide Number: 89250012 Published by: ESAB Group Inc. 2800 Airport Ra. Denton, TX. 76208, 940-566-2000 \worw.esab.com/arcair Copyright © 2013 ESAB All rights reserved. Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited ‘The publisher does not assume and hereby disclaims any lability to any party ‘or any loss oF damage caused by any error or omission inthis Manual, whether such errar results from negligence, accident, or any other cause. For Printing Material Specification refer te document 471920 Publication Date: September 23, 2016 Revision Date: June 15, 2017Table of Contents SECTION 1: INTRODUCTION. 1 101 i Caor-re Cuting/Geugg 1 1.02 HistO1y nnn 1 1 1 1.08 Applications... 4.04 The "BEST Just Got Better. ‘SECTION 2: SAFETY AND HEALTH... 2.01 Proper Installation, Use, and Maintenance 2.02 Electrodes : 2.08 Ventilation Hazards 7 2.04 Persona Protev Equipment an Clahing 2.06 Shielding BoOthS......2u os 2.06 Fire and Burn Hazards... 2.07 Satety and Operating References. SECTION 3: HOW TO USE THIS MANUAL. 3.01 Receipt of Equipment SECTION 4: INSTALLATION .. 4.01 Installing the DC Welding Power Cable and Air Hose ta the Power and Air Connector... vernon dd 4.02 Instaling the DC Welding Power Cable with Twist Lock Pawer Connection and Air Hose to the Torch ‘Swivel Cable Assembly 44 4.08 Connecting to DC or AC Welding Power Supplies. 45 ‘SECTION 5: TROUBLESHOOTING .....-...coceneene 51 ‘SECTION 6: REPLACEMENT PARTS 3000™ & 4000” Torch Replacement Parts. ‘STATEMENT OF WARRANTY. INSIDE BACK COVER POWER & AIR HOOK-UP KIT HOOK-UP KIT & PARTS LIST ea] oan em Crore pK! [oe 7 [teen ase [rR Gaerc [aR se 6362 (CABLE REPLACEMENT PARTS LIST ea Deion eco [OO TR eM Swale | 7ooebo7_| Toose207 “on em Sette | Toawe-1i0| Toase2i0| 7 Teer 5 56 z nha seriocar | otrrose2* 3 omic Era o Spo me cow | orseroe o Fata eras | otae-05 5 | camp eres | se-tera10 | ea-er-ci0 7 Levan | oetansie [ wena Tonto | eects | oes. Y 7H Cot women | ema To oH coe pernae | weaniare ee | _ferae acer | aero err-80 rs ines Sen Rng et SECTION 1: INTRODUCTION coxy-fuel cutting (OFC). Gouging or cutting occu’s when the intense heat of the arc between the carbon electrode and the workpiece melts part of the workpiece. Simutta- ‘neously, air passes thraugh the arc quickly enough to blow the molten material away. ‘The air carbon-are process does not require oxidation to maintain the cut, so it can ‘gouge or cut metals that the OFC process cannot. Most common metals (e.g, carbon steel, stainless steel, many copper alloys and cest irons) can be cut using the air carban-are process. The metal removal rate degends on the melting rate and how efficiently the air jet removes molten metal. Inthe process, the air must It the motten metal ciear of the arc before the metal solidifies. 1.02 History Ar carbon-are gouging began in the 1940's, evolving from the existing carbon-arc cut- ting process. Myron Stepath, a welding engineer, developed air carbon-arc gouging to remove several hundred feet of flat, racked, stainless steel wel. Previously, carbon-are cutting removed overhead and vertical defective welds and rivet heads, The carbon-arc melted the metal, then gravity moved the molten metal away. Stepath reasoned that an air jet could provide the force to remove metal ling flat. So he tied a direct-current, electrode-negative carbon-arc with a second operator direct- ing an air blast via air nozzle atthe molten pool However, this attempt was unsuc~ cessful because the arc was less stable than a carbon-welding arc. So, Stepath tried a direct-current, electrode-positive arc, and the result was air carbon-arc gouging. [In 1948, Myron Stepath introduced the fist air carbon-arc torch to the welding indus try, In 1949, Stepath and two associates foundsd the Areair Company. ‘Two operators were no longer needed. The compressed air now passed through the torch and exited beneath the electrode, This new tool saved time on weld backgouging,, crack removal, and weld defect repair on carben, alloy, and stainless steel. Previously, these tasks were performed by grinding or chipping. Today, the basic principle remains the same, but with improved equipment and an ‘expanded number of applications. 11.03 Applications ae ‘The industry has enthusiastically adopted air carbor-arc gouging and found many uses forthe process in metal fabrication and casting finishing, chemical and petroleum technology, construction, mining, general repair, and maintenance. Arcair Torches and Electrodes are used throughout the world, anywhere metal is (Qouged, grooved, severed, or removed from a surface. ‘The air carbon-are process is flexible, efficient, and cost effective on practically any metal: carbon steel, stainless steel and other ferrous alloys; gray, malleable and ductile iron; aluminum; nickel; copper alloys and other nonferrous metals. 1.04 The "BEST" Just Got Better. Aair is changing the game when it comes to the power and air connection design on their K-Series torch cable assemblies, Since the invention of the air carbon-arc process in 1949, the torch and cable have always used a molded rubber “boot' to provide electrical protection for the power connection by preventing arcing against a grounded work surface. This boot design incorporates a large open rectangular end that allows the power cable and air hose space to connect to the torch cable. However, the boot can expose the power Connection to the grounded work surface if tis not properly installed and Kept in place ‘over the connection, ‘Now, the improved boot design encapsulates the power/air connection, eliminating the chance of accidental arcing. It can accept one 4/0 welding cable from the power supply and one %" diameter air hose assemly that provides current and compressed air, This new boot design is molded from a hard nylon reinforced fiber material that can withstand the abuse of everyday use in a fabrication shop. SECTION 6: REPLACEMENT PARTS K3000™ & K4000° TORCH REPLACEMENT PARTS ‘TORCH REPLACEMENT PARTS LIST eT a0 00 1 [testo & Sees 96-69-105 8-183 | tard See e080 Bea 3 |__ vate onwe orDeoi peor [tenet Wench ean o 6001 = Barnet Oy oepeo rior? © | Spal binge emo aor z OF TOD ‘e708 @ Sean Ory em oeaorara = Upper ee a0 Semen 10 [Yeas Seen ee 8 ere 1 Tore Bad Bene 108206 a Tine Pi DEB IOH ee 084 on Sera oe 91 ean 1 Tans emo S065Problem Solution ‘In gouging, tree carbon epost a vary ‘groove intervals; in pad “washing, free carbon deposits at various spots on the washed surface. 1. Ashorted electrode on the workpiece, In manual gous, this 'sa result of excessive Nravel speed forthe amperage used and for the depth of the groove bing made, In mecha- nized operations, this is a result of excessive ‘travel speed oF usin afat-curve, censtant- Voltage povier source for a small diameter electrode 5/16 (7,9 mm. in padwashing, {hss caused by hold ing the electrode at too _sialla push angle Use an electrode-to-vork angle of 15° to 70°. A ‘smaler angle increases the arcing area reducing ‘the current density his reduction in are-curent density requires a great decrease i arc length to {he point of short circ Keep a proper arc gap. Irregular groove: too deep, then too shallow. 1. The operator was unsteady, The operator should assume a comfortable Position while gouging. Slag adhering to th edges of the groove. 1. Slag sition was inadequate, To resoWve, keep a proper air pressure and flow rate cfm). Air pressure be~ en 80 and 100 psi (550-690 kPa) may not Gtiectively jetta of the slag f the volume is insufficient, To deliver adequate volume, the air hose feeding the concentric cable assembly needs minimum hose ID of 18" (8.5 mm) for manual torches. For automatic torches, the minimum, hose ID'should be 1/2" (12.7 mm), Direct thea Jet parallel tothe gouge area. Do not favor one Side unless operator wants to minimize slag ‘rom adhering to one side of te cl 52 This Page Intentionally Blank14 This Page Intentionally Blank SECTION 5: TROUBLESHOOTING Problem ~ Solution Large free-carbon de- osit atthe Beginning of ie groove. 1. The operator ether ne- lected to tun onthe jet before strking the are or the torch Was located imprapery. 2. Carbon rod rot posi- toned property nad assembly 1. Turn on air before strik- ing the arc and ar shoul flow between the elec- ‘rode and the workpiece. 2. Ensure carbon rod is seated in groove in torc head. ld h ‘An unsteady are, causing the operator to use a slow travel speed even ‘on shallow grooves. 7. Not enough amperage for the electrode diam- eter used (see Tabla 2). While thelowest ‘recommended amper- ago may be enough tt regu preter Opera tor skill A md-range amperage isbeter T. Ihe desired amper age cannat be obtained ‘rom the avaiable Dower source, use the next smaller diameter electrode or parallel two ‘or more welding power supplies. Erratio groove with the arc wandering from, side-to-side and with the electrode heating up rapidly. 7. The process used with CEN (electrode nega- tive) 1. Gouging process should bbe done with DCEP (Ele {rode positive) whenever Possible. Direct curent electrodes should be used with OCEP (elec- trode positive) on al ‘metals, except for afew copper alloys such as Superston and Nialite o Intermittent are action ‘esulting in an irregular ‘groove Surface. 7. The travel speod was ‘oo slow in manual gouging, the opera. or possibly st the hand on other work for balance, a terdency in shielded metal-arc welding, Since the Speed of air carbon-are gouoing fs much aster an shielded metal-are welding, frion be- tween the gloved hand and the wortpiece may Cause a jerky forward ‘motion thus causing the gap between the electrode and work- jece to became too large to mairtan the at 2. Poor ground connec- tion, 1. The operator should sland comfortably so their arms move freely and their gloves do not Grag on the workplace. it using mechanized equp- ment, check ‘Table’ (Page 4-24) for proper operating cond- ions. 2. Inspect ground clamps ‘and lead{s) to ensure Connection proper. 54This Page Intentionally Blank 48 SECTION 2: SAFETY AND HEALTH ‘Safe practices in welding and cutting processes, such as air carbon-arc, are covered in ANSI 249.1, “Safety in Welding and Cutting", and ANSI 249.2, “Fire Prevention in Use of Welding and Cutting Processes.” Air carbon-are operators and their supervisors should adhere to the safe practices discussed inthese documents. Other hazards in arc welding and cutting are briefly discussed in this section. 2.01 Proper Installation, Use, and Maintenance Serious injury or death may result if gouging and cutting equipment isnot properly installed, used, and maintained. Misuse ofthis equipment and other unsafe practices can be hazardous. The operator, supervisor, and helper must read and understand the following safety warnings and instructions before instaling or using any air carbon-arc torch or equipment. ‘The gouging/cutting process is used in many potentially dangerous environments, such as elevated heights, areas with limited ventilation, close quarters, areas around Water, hostile environments, etc. The operator must be aware of the dangers associ- ated with working in these types of conditions. The operator must be trained in safe practices for his work environment and be under competent supervision. Its essential thatthe operator, supervisor, and others in the work area be aware of the dangers of the ar carbon-arc process. Training and proper supervision are important for a safe work place. Keep these instructions for future use. Additional recommended safety and operating information is referenced in each section = = 2 J WARNING. ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH The purchaser is responsible forthe safe instalation, operation, and use of all products purchased, including compliance with all applicable ISO standards ‘and local codes in the country of use. Do not service or repair equipment with power an. Do not operate equipment with protective insulators or cov- ers removed. Service or repair to equipment must be done by qualified and/ or trained personnel only. aKeep carbon electrodes dry. If electrodes become damp, bake them for 10 hours at 300" F (176°C). Wet electrodes may shatter, Do not touch electrically live parts. Do not touch an electrode with bare skin and electrical ground at the same time. Always wear dry welding gloves that are in good Condition. Aluminized protective clothing can become part ofthe electrical path. Keep ‘oxygen cylinders, chains, wie ropes, cranes, hoists, and elevators away from any part ‘of the electrical circuit. Check all ground connections periodically to determine i they are mechanically strong and electrically adequate for the required current I you are engaged in alternating current gouging/cutting under wet conditions or ‘warm surroundings where perspiration is a factor, use reliable automatic controls for reducing no load voltage to reduce shock hazard. When the gouging/cutting process requires values of open circuit voltages in alternating current machines higher than £80 volts, and direct current machines higher than 100 vols, take precautions, such as using adequate insulation, to prevent the operator from making accidental contact with the high voltage. I you are going to suspend gouging for any substantial period of time, such as during lunch or overnight, remove all electrodes from the torch and the put the torch ina safe location so that accidental contact cannot occur. Disconnect the torch from the power ‘source when itis notin use. Never immerse air carbon-are torches or electrodes in water. 2.03 Ventilation Hazards = WARNING SIMOKE, FUMES, AND GASES CAN BE DANGEROUS TO YOUR HEALTH Keep smoke, fumes and gases from the breathing area. Fumes from the gouging process are of various types and strengths, depending on the kind of base metal being ‘worked on. To ensure your safety, do not breathe these fumes. Ventilation must be ‘adequate to remove smoke, fumes and gases during the operation to protect gouging operators and others in the area. \Vapors of chlorinated solvents can form the toxic gas phosgene when they are ‘exposed to ultraviolet radiation from an electric arc. Remove all solvents, degreasers, and potential sources of these vapors from the operating area, Fumes that are produced by cutting in particularly confined places can cause discom- {ort and physical harm if inhaled over an extended period of time, Provide adequate ventilation in the gouging/cutting area. Use alr-supplied respirators if there is not enough ventilation to remove all fumes and gases. Never ventilate with oxygen, be- cause oxygen supports and vigorously accelevates fire, 22 9. Lightly touch the electrode to the workpieceto establish the ar. Do not draw back the electrode once the arc is ignited. When the correct arc voltage is being maintained, the sound ofthe arc and the compressed air is oud. When the sound is mulied, the ac voltage is below the recommended operating conditions. Normal arc voltage ‘witha handheld gouging torch is measured between 35 to 50 volts. 10. The groove's depth is controlled by travel speed. Grooves up to 1” (25 mm) deep may ‘be made, However, the deeper the groove, the more experienced the operator needs to be. Slow travel speeds produce deep grooves, and fast travel speeds produce shallow ‘grooves. The width of the groove is determ ned by the size ofthe electrode used and 's typically about 1/8" (3.2 mm) wider than the electrode’s diameter. A wider groove ‘may be made with a small electrode by oscillating ina circular or weave motion.TORCH ELECTRODE TORCH HEADS (+ KK” 2.04 Personal Protective Equipment and Clothing a WARNING NOISE CAN DAMAGE HEARING. Noise from the air carbon-arc process can damege your hearing. Operators and sur- rounding personnel must wear adequate protective hearing devices to ensure personal WORKPIECE -) protection against noise when noise levels exceed OSHA standards Figure 412 = Duration Por Day (hi Sound Level GBA") Siow Response 6. Hold the electrode as shown in Figure 4-12, so that a maximum of 7" (178 mm) ns sean si EL — espe extends from the torch. This extension should be 3° (76.5 mm) for aluminum. = 6 7. Adjustthe welding current (Constant Curret) or voltage (Constant Voltage), depend a s ing on the type of power supply being use, to the suggested current range shown for the carbon diameter being used. Refer to Table 4-1. 3 Ci Table 4-1 - Suggested Current Ranges (AMP) for Commonly Used Electrode Types and Sizes 2 400 Electrode | DC Electrode DCEP| AC Electrode | AC Electrode DCEN 442 ioe, Diameter AC 1 105; Tamm) in = max min-max thin = max Wor ess 115 1 zi GBA als 8 (3.2) 60-90 vik 5182 (40) 90-160 3/16 (48) 200 = 250 200-250) 150-180 11464) 300-400 300 - 400 200-250) 3 ares. 3716 (79) 350-450 Wa ———— SD BGO 78 (95) “asa 0 PTET) ARG RAYS, HOT SLAG, AND SPARKS CAN INJURE IW SKIN TR U2.7) 800-1000 15.9) zi ee a ! ee ‘The gouging/cutting process produces extreme localized heat and strong ultraviolet 3/4 (19-1) peso tea WA rays. Never attempt to gouge/cut without a welding helmet with the proper ens that 1 (25.4) 1600 - 2200 complies with federal guidelines, 374(0.5) FLAT 230 2450 ‘number 12 to 14 shade filter lens provides the best protection against arc radiation, 5/8 (9.5) FLAT 300 = 500 When in a confined area, prevent the reflected ar ray from entering around the hel- 8. Tum on the air jet before striking the arc. Hold the torch between a 45° - 60° work angle, so thatthe electrode slopes back rom the direction of travel. The ar jet sweeps between the electrode and workpiece, providing the force to remove all molten metal from the groove 46 met. Make sure others are protected from arc ays and sparks. Use approved shielding curtains and appropriate goggles to provide protection to others in the surrounding area and operators of nearby equipment. 23‘Skin should also be protected from arc rays, heat and molten metal. Alvays wear protective gloves and clothing that will not allow skin to become exposed. Close all Dockets and sew shut al cutfs, Wear leather aprons, sleeves, leggings, ete. for out-of- position gouging/cutting, or for heavy metal-emoval operations using large elec- trodes. High top work shoes provide adequate protection from foot burns. Use leather spats for added protection. Do not use flammable hair preparations when gouging! cutting. Wear earplugs to protect ears from sparks. 2.05 Shielding Booths ‘Where the work permits, the arc welder should be enclosed in an individual booth painted with a finish of low reflectivity—an important factor for absorbing ultraviolet radiations—such as zine oxide and lamp blac. The welder may also be enclosed in similarly painted noncombustible screens. 2.06 Fire and Burn Hazards ane Ca WARNING WELDING SPARKS CAN CAUSE FIRES AND EXPLOSIONS. ‘Causes of fire and explosion include combustibles reached by the arc, flame, flying sparks, hot slag or heated materials. Remove combustibles from the work area and/or provide a fire watch. Avoid olly or greasy clothing as a spark may ignite them. Keep a fire extinguisher nearby, and know how to use it. Be alert to the danger of conduction or radiation. For example i you will be gouging/ cutting on a metal wall, partition, ceiling or roof, take precautions to prevent com- bustibles from igniting on the other side, Do not gouge/cut containers that have held ‘combustibles. Vent all hollow spaces, cavities and containers before gouging/cultting to permit air or gases to escape. Purging with inert gas is recommended. 24 4.03 Connecting to DC or AC Welding Power Supplies Gouging applications normally use three-phas2 welding power supplies with an open circuit voltage higher than 60 volts, to allow for any voltage drop inthe circuit 41, Connect the Welding Power Cable that is connected to the Torch Swivel Cable to the positive terminal on the power supply (DCEP or AC). Refer to Figure 4-11 2. Connect the Welding Power Gable that is connected to the negative terminal on the ower supply to the workpiece. coupnesser AR PoweR suPPLY (REVERSE POLARITY) ELECTRODE LEAD ‘OCEP OR AC « CONCENTRIC: CARBON ELECTRODE WoRKPIECE WORKPIECE LEAD Figure 4-11, 3. Tum on the power supply and air supply tc the gouging torch and cable assembly ‘While the torch valve is open, adjust the airpressure at the torch to the normal pres ‘sures range between 80 psi (551.6 kPa) znd 100 psi (690 kPa); higher pressures ‘may be used, but they do not remove metal more efficiently. 5. Press down on the lever of the torch to insert the air carbon-arc electrode “carbon” into the torch. When using copper coated carbons, the bare carbon end should be down and away from the torch. This is where the arc wil be struck between the carbon and workpiece. Refer to Figure 4-12. A WARNING Carbon is aletrcally HOT at this point 45410, Reposition the top half ofthe boot in place and secure with the four (4) screws that were removed in step 3. Figure 4-10 14, The assembly is now ready to be used in your metal removal application. 4.02 Installing the DC Welding Power Cable with Twist Lock Power ~ Connection and Air Hose to the Torch Swivel Cable Assembly Models Part No. 61-065-002, 61-065-003, 61-082-006 and 61-082-007 1. Remove the Torch and Cable Assembly from the carton and lay the assembly in a straight and untwisted position on a workbench or floor. 2. Remove the Twist Lock Connector attacved to the Torch Swivel Gable Assembly. Follow these steps to connect the brass female connector to the DC Power Cable: a. Remove the cover screw holding the outer cover in place from the assembly. ‘Trim the rear of the connector covert fit the cable being used. NOTE: Do not cover trim, The cover should fit snugly. ©. Slip the cover over the cable. ‘Trim the cable insulation back 1-7/8", exposing the copper stranding, Loosen the ball-point screws and insert the copper cable into the cable hole of ‘the brass connector hait. {Tighten the ball-point screws securely (150 ~ 250 in./bs.) The heads of the screws should be flush with, or below, the connector body. 4. Slip the connector cover over the brass body and installtighten the cover sorew. The screw fits into the secord cover hole, 3. Thread the 3/8" pipe threaded fitting thatis connected to the Air Hose coming out of the Torch Swivel Cable, into your shop airline. This connection should be wrench tight. 44 Table 2-1 - Recommended Minimum Air Requirements Recommended Compressor Rating Air Air “ ‘ASME ‘Type of Torch | Pressure’ | Consumption ets ee Receiver psi (KPA) | efm (L/min.) ‘Size ‘hp (kW) ‘hp (kW) ‘al (lt) Light Duty _| 40 (280) 8 (227) 0.5 (0.4) 4.5 (1.1) 60 (227) General Duty? 25 (708) 5 (3.7) 7.5 (5.6) ‘Multipurpose? 33 (934) 7.5 (5.6) 40 (7.5) 80 (303) ‘Automatic’ | 60 (414) | 46 (1303) NA 15 (11.2) “Pressure whlch in operation * accommodates fat electrodes. 2 Generally considered a foundry tach “quires some kind of mechanical manipulation Use only compressed alr. Using combustible compressed gases can cause explosions that may resutt in personal injury or death, 2.07 Safely and ‘Operating References +. Gode of Federal Regulations. (OSHA) Seton 29 Part 1910.85, 122,193, 14,190, 251, 252, 253, 254 AND, 1000. U.S. Goverment Printing Office, Washington, DG 20402 2, ANSI 249.1 “Safety In Welding and Cutting” 3, ANSI 287.1 “Practice for Occupational and =ducational Eye and Face Protection.” 4, ANSI 288.2 “Standard Practice for Respiratory Protection.” American National Stan- dards Institute, 1480 Broadway, New York, NY 10018. 5. AWS 05.3 “Recommended Practices for Air Carbon-Arc Gouging and Cutting.” 6. AWS FA.1 “Recommended Safe Practices for Welding and Cutting Containers.” The American Welding Society, 550 NW L3jeune RD., PO. Box 351040, Miami FL. 33135 7. NFPA 518 “Fire Prevention in Cutting and Welding Processes” National Fire Protec tion Association, Battery Park. Quincy MA 02269 8, CSA Standard W117.2, “Safety in Welding. Cutting and Allied Processes” Canadian ‘Standards Association, 178 Rexdale Blvd., Rexdale, Ontario, Canada MOW 1R3 80 (550) 26This Page Intentionally Blank 26 8. Liftthe assembly away from the bottom talf of the boot to securely fasten. Do not allow the crimped lug to move while doing this final tightening step. Fue 47 9. Thread the incoming Compressed Air Line with a 3/8” pipe threaded fitting into the Power and Air Connector. This connection should be wrench tight. Figure 4-8 10. Reposition the Cable Assembly with the DC Welding Power Cable and Air Hose back in place in the lower half ofthe boot. Figure 4-94. Using a 54"-13 x 1” hex head bolt, pesition the bolt down so that its threads run through the crimped lug of the DC Welting Power Cable and through the Power and Air Connector on the Swivel Cable Assambly. The head of the bolt should be against the flat side ofthe crimped lug as shown in Figure 4-4 5. Place a ¥" lock washer over the bolt threads and begin to thread a against the assembly, 13 nut down gure 4-4 6. Position the brass Power and Air Connector back into the bottom half ofthe boot Figne 4s 7. Using your index finger to apply an upward force on the bol, tighten the assembly down, Fire SECTION 3: HOW TO USE THIS MANUAL ‘To ensure safe operation, read the entire mansal, including the chapters on safety instructions and warnings, Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings, These special Annotations are easily recognized as follows: ‘A WARNING GIVES INFORMATION REGARDING POSSIBLE PERSONAL INJUBY. A CAUTION, A CAUTION refers to possible equipment damage. NOTE ANOTE offers helpful information concerning certain operating procedures. 3.01 Receipt of Equipment When you receive the equipment, check it against the invoice to make sue it is com- plete and inspect the equipment for possible damage due to shipping I there is any ‘damage, natiy the carier immediately to filea claim. Furnish complete information ‘concerning damage claims or shipping erars to the location in your area listed inthe inside back caver of this manual, Include a ful description ofthe parts in error 34.This Page Intentionally Blank SECTION 4: INSTALLATION 4.01 Installing the DC Welding Power Cable and Air Hose to the Power and Air Connector Models Part No, 61-065-006, 61-065-007, 61-082-008 and 61-082-009 Follow these instructions to connect the DC Welding Power Cabla and Compressed Air Line directly tothe Power and Air Gonnector on the Torch Swivel Cable Assembly 1. Remove the Torch and Cable Assembly from the carton and lay the assembly in a straight and untwisted position on a workbench or floor 2. Position the molded boot so that you have access to the four (4) screws as shown in Figure 4-1 Figure4-t 3. Use a straight blade screwdriver to remove the four (4) screws. Lift the top half of the molded boot away from the assembly. Figure 42 Figue 43 44